LEAB BPC 12-12-40 Charge Booster User Guide

LEAB BPC 12-12-40 Charge Booster

About this Manual

Read this manual carefully and keep it in a safe place. This manual is aimed at Skilled workers in the field of automotive electrics . Any modifications to the product or its components are prohibited and do not conform to its intended use. Only use original LEAB or LEAB-approved ac-cessories. Throughout the manual, you will be alerted to warnings and safety notices about potential hazards associated with handling the device. The colours and signal words indicate the severity of the hazard:

Notice
Possibility of material damage The signal word Attention indicates that there is a possibility of material damage. To avoid material damage, follow the instruction.

CAUTION
The danger that can lead to minor injuries A safety instruction with the signal word CAUTION denotes a hazard with a low degree of risk which, if not avoided, can result in minor or moderate injury. Read the safety information carefully and follow the instructions to avoid it.

WARNING
Hazards that can lead to severe injuries or death
A safety instruction with the signal word WARNING indicates a hazard with a high degree of risk which, if not avoided, will result in death or severe injury. Read the safety information carefully and follow the instructions to avoid it.

DANGER
The danger that will lead to severe injury or death A safety instruction with the signal word Danger indicates a hazard with a high degree of risk which, if not avoided, will result in death or severe injury. Read the safety information carefully and follow the instructions to avoid it. You will find notes at some points in the manual. These appear as follows:

NOTE
A note provides useful tips and information about the product. Read the note carefully and follow the instructions where applicable.

2 General Safety

This manual will help you to handle the device safely. Use the device solely in accordance with its intended use. Observe the safety instructions.

WARNING
Risk of burns from hot surfaces During continuous operation, the surface of the device can reach temperatures of up to 70 °C.
1. Avoid physical contact with the device during operation.

WARNING
Burns from escaping acid Acid can leak out when handling batteries.
1. Wear acid-proof clothing when handling batteries.

WARNING
Risk of fire from overheated battery Flammable gases can escape if the battery overheats.
1. Always charge batteries in well-ventilated rooms and away from ignition sources.

Notice
Device defects from incorrect installation can result in device defects.
1. Install the device in a dry and cool location.

2.1 Intended Use

The BPC charge booster is an active DC-DC converter that charges the addi- tional battery from the on-board supply system. Using the voltage at the input, the modern voltage converter generates a regulated charging voltage for fast recharging of lead batteries (wet, gel and AGM batteries) or lithium batteries during travel.
At the output, the system supplies an adjustable DC voltage between 14.1 V and 15 V and thereby provides consumers with power permanently or for a short time. The input voltage is 12 V.
The device is designed for an operating temperature of -20 °C … +50 °C. A re- duced output current is generated from surface temperatures of 70 °C.

2.2 Foreseeable Misuse

The device is designed for interior use only. Do not mount the device outside the vehicle.

LEAB Automotive GmbH

4 Technical Specifications

Modell                                                    BPC 12-12/40

Input voltage                                           12 V (11.5 V … 15 V)

Output voltage                                          14.1 V/14.5 V/15 V (adjustable)

Output current, max.                               40 A, reduced output current from 70

°C surface temperature

Input current, max.                                    55 A

Standby current, max.                         < 10 mA

Degree of efficiency                               > 95 %

LEAB Automotive Gmb
H Part no. 1041003001

Operating temperature                                 -20 °C … +50 °C

International Protection (IP class)           IP21

DC connector                                        Bolt, M8 (max. 15 Nm)

Operating display                                 LED

Dimensions (L x W x H)                               170 mm x 137 mm x 70 mm

Weight                                                         900 g

**5 Package Content

**                                                    No.

BPC charge booster                           1x

Insulating caps (red)                               2x

b                                                          1x

6 Preparation

NOTE! If you are using a Clayton Power lithium battery and CAN communication, there is no need to set the output voltage as it is detected automatically.
Before you install the BPC charge booster, the required output voltage must be set. To do this, perform the following steps:

Connect the 12 V battery (DC Input)
To connect the starter battery, perform the following steps:

1. Disconnect the starter battery from the on-board supply system.
   WARNING! Disconnect the negative cable first.

2. Secure the positive cable as close as possible to the starter battery with a suitable fuse (60 A).

3. Connect the positive terminal of the starter battery to the DC input of the device with a cable (25 mm2).
   CAUTION! First connect the charge booster and then the starter battery. NOTE! Loosen only the top nut.

4. Connect the negative terminal of the starter battery to the port for the ground (GND) of the device with a cable (2.5 mm2).
   The device is ready for operation (‘LED Status’ flashes green).

5.  Connect the starter battery to the on-board supply system.
   The BPC charge booster is connected to the starter battery.
   Setting the Output Voltage
   The BPC charge booster provides 3 different output voltages:– 14.1 V for wet batteries
   – 14.5 V for gel and AGM batteries
   – 15 V for lithium batteries
   An output voltage of 14.1 V is set at the factory.
   To set the output voltage, perform the following steps:

6. Press the program button (approx. 6 seconds) until ‘LED Failure’ and ‘LED Status’ illuminate green.

7. Press the program button for a further 3 seconds.

8. To choose between the output voltages, press the program button.
   – LED Com: 14.1 V
   – LED Failure: 14.5 V
   – LED Status: 15 V

9.  To store an output voltage, press the program button for 3 seconds until all LEDs illuminate red.
   The output voltage is set. To check the set output voltage, see Checking the Set Output Voltage [} 12]

. 7 Assembly

Notice

Device defect due to the effects of dust and moisture The effects of dust and moisture can cause device defects

1. Choose a cool, dry and well-ventilated assembly site.
2. Protect the device from the effects of dust and moisture.

To assemble the device, perform the following steps:

Assemble the device on a flat and heat-conductive surface. 1 Fasten the device with screws to the 4 lateral holes (Ø 4 mm). The device is assembled.

8 Installation

To install the device, perform the following steps:

1. Disconnect the starter battery from the on-board supply system.
   WARNING! Disconnect the negative cable first.

2. Secure the positive cable as close as possible to the starter battery with a suitable fuse (60 A).

3. Connect the positive terminal of the starter battery to the DC input of the device with a cable (25 mm2).
   CAUTION! First connect the charge booster and then the starter battery. NOTE! Loosen only the top nut.

4. Connect the negative terminal of the starter battery to the ground port (GND) of the device with a cable (2.5 mm2). The device is ready for operation.

5. Connect the positive terminal of the additional battery to the DC output of the device with a cable (25 mm2).
   NOTE! Loosen only the top nut

6. Connect the negative terminal of the additional battery to the shared ground with a cable (25 mm2).

7. Connect the D+ signal of the vehicle (e.g. terminal 15 or terminal 51) with the port for the D+ signal of the device.
   NOTE! When used with lithium batteries from Clayton Power, the vehicle’s D + signal can also be transmitted via the device’s CAN communication connec- tion.

8. Connect the starter battery to the on-board supply system. The device is installed.

8.1 Connecting an External LED

To connect an external LED, perform the following steps:
1 Connect the anode lead of the external LED to the DC input of the device. 2 Connect the cathode lead of the external LED to the of external LED port on the device.  The external LED is connected.

8.2 Establishing CAN Communication

The BPC charge booster is used to facilitate easy charging of lithium batteries from Clayton Power. The BPC charge booster is switched on and off via CAN communication. In addition, the charge booster automatically detects the re-quired output voltage.
To activate CAN communication, perform the following steps:
1 Connect one end of the CAN communication cable to a CAN bus connector on the Clayton Power lithium battery.
2 Connect the other end of the CAN communication cable to the CAN connector on the charge booster.  CAN communication is established automatically during operation.

9 Operation

9.1 Switching the Device On/Off

The BPC charge booster switches on automatically when the following condi- tions are fulfilled:

– D+ signal is present (connection for D+ or CAN communication).
– Charger booster is in standby mode.

The BPC charge booster switches off automatically when one of the conditions is not fulfilled.

9.2 Changing the Output Voltage

NOTE! If you are using a Clayton Power lithium battery and CAN communica- tion, there is no need to set the output voltage as it is detected automatically.

LEAB Automotive GmbH
The BPC charge booster provides 3 different output voltages:

– 14.1 V for wet batteries
– 14.5 V for gel and AGM batteries
– 15 V for lithium batteries

To change the output voltage, perform the following steps:

The device is ready for operation and is not charging a battery.
1 Press the program button (approx. 6 seconds) until ‘LED Failure’ and ‘LED Status’ illuminate green.
2 Press the program button for a further 3 seconds.
3 To choose between the output voltages, press the program button.

– LED Com: 14.1 V

– LED Failure: 14.5 V

– LED Status: 15 V

4 To store an output voltage, press the program button for 3 seconds until all LEDs illuminate red.  The output voltage is set.

9.3 Checking the Set Output Voltage

To check the set output voltage, perform the following steps:

The device is ready for operation.
1 Press the program button (approx. 6 seconds) until ‘LED Failure’ and ‘LED Status’ illuminate green.
2 Press the program button for a further 3 seconds.
LEDs illuminate in a chase string. LED for the set output voltage illuminates green.

9.4 Operating Status

The BPC charge booster indicates the operating status via the LEDs on the charge booster. In addition, an external LED can be connected.

LEDs on charge booster

protection (from 70 °C surface temperature)
LED Status| Flashes green| Device is ready for operation
LED Status| Flashes alternately red and green| Device in normal operation, charging current is limited
LED Com| Illuminates yellow| CAN communication active
LED Com| Does not illuminate| CAN communication inactive
LED Failure| Flashes red| See Error Descriptions table in the Error Codes and Error Descriptions [} _13]_section

With External LED

Tab. 2: With External LED
10 Error Codes and Error Descriptions
Displaying Stored Error Codes

To display error codes, perform the following steps:
1 Press the program button until ‘LED Com’ and ‘LED Failure’ flash green.
2 The error codes are indicated by the flashing of ‘LED Failure’ (see Error Description table)

NOTE! The first error code displayed is the most current error code. The device stores up to 5 error codes.

11 Maintenance

Maintain the device at regular intervals:

– Ensure that the wiring between the batteries and the charge booster is se- cure.
– To remove dirt, clean the device from the outside with a dry cloth.

12 Disposal

Dispose of the device in accordance with the Waste Electrical and Electronic Equipment Regulations (WEEE).
The system must not be disposed of with household waste. Take it to a recycling point or return it to your point of sale.

13 EU Declaration of Conformity

The BPC 12-12/40 charge booster complies with the requirements of the following directives:

– 2014/30/EU: EMV
– 2011/65/EU: RoHS

LEAB Automotive GmbH Thorshammer 6
DE-24866 Busdorf
Tel: +49 (0) 4621 9 78 60-0 Fax: +49 (0) 4621 9 78 60-260 [email protected]

It is prohibited to copy, duplicate, translate or otherwise pass on the content of this guide to third parties without the express written permission of LEAB.

References

• Spezialist für mobile Stromversorgung // LEAB // mobile energy

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